Segmented Insole for Support of Embedded Systems

ABSTRACT

A two part insole having one part for housing smart systems embedded within an insole, and a second part for maintaining comfort of a cut-to-fit insole to increase the functionality of the overall product for the user.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 61/873,421, filed Sept. 4, 2013.

BACKGROUND OF THE INVENTION

Smart footwear is defined as footwear having embedded mechanical andelectrical systems for performing various functions. Embedded systemsmay be located anywhere on the shoe, but it is desirable, both forfunction and aesthetic reasons, that the embedded system be hidden inthe insole of the shoe. Typical examples of such systems include energyharvesting devices, footwear-embedded GPS devices and step-logging(pressure sensing) devices. Devices hidden in the insole of the shoerequire support material for the embedded device to prevent damage fromimpacts from the user's foot and from moisture that may be presentwithin the shoe.

Off-the-shelf after-market insoles are frequently made to be cut-to-fit.A range of sizes will be marked on the insole so that the user can cutthe toe end of the insole to personalize the size. However, optimalfitting depends on user precision, and the insole can easily be ruinedby user error, rendering the entire system unusable. For an insolewithout an embedded system, two insoles are typically offered forpurchase in one package, or the user can buy another insole for arelatively low cost if the insole is ruined by user error.

Insoles for smart footwear, however, have a much higher expected costand cannot be repurchased as easily. Other problems related to embeddedsystems within insoles include added wear on those systems from machinewashing, replacement of the soft (comfort-related) materials from wear,and the high cost of customization due to aesthetic desires like color.Therefore, it is desirable to provide an insole design that addressesthese deficiencies, while supporting a wide variety of embedded systems.

SUMMARY OF THE INVENTION

A novel two part insole is presented for use with any mechanicalmechanism or electronic device located in the heel of an insole. The twopart insole construction is designed for both stability and support ofthe embedded system present in smart footwear, as well as for comfort ofthe user, while still addressing the cut-to-fit and reusabilityconstraints desirable for insoles.

The insole is provided as a two-part construction having a bottom layerand a top layer. The bottom layer is a more rigid construction andprovides stability and encasing for engineered systems. The top comfortlayer is detachable from the bottom layer, is customizable by material,color, and size, and consists of a softer, more flexible material forthe comfort of the user. The insole layers may be attached to each otherusing grooves, adhesives, or detachable materials like Velcro. The toeend of the top layer of the insole may be provided with a cut-to-fitpattern for user fitting, or maybe provided pre-sized from the factory.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an exploded view of the segmented insole of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

Smart footwear having engineered devices embedded in the insole are bestserved by a two part insole where the cheaper, top comfort layer 1 ofthe insole can be customizable and removable, while the lower, morerigid layer 2 supports the embedded device. The present invention is atwo part insole for this purpose. The system includes an upper insolelayer 1 for comfort, having cut-to-fit lines on the toe end thereof forcustomizability, and a lower insole layer 2 for support, having a cavity5 of variable shape for embedding mechanical and electrical systems. Anattachment method between the lower support 2 and upper comfort insolelayer 1 is provided. The insole may also feature treads on the base ofthe insole for inducing friction between the insole and the base of theshoe.

The smart footwear insole of the present invention is shown in FIG. 1.Top, comfort layer 1 is thin at the heel-end, becomes thicker under thearch at the arch point, and tapers to be thinner by the toe end. A notch4 at the arch point is shaped to mate with bottom support layer 2.Cut-to-fit lines 3 are marked on comfort layer 1, such that the user cancut comfort layer 1 to their personal foot/shoe size along one ofcut-to-fit lines 3.

Comfort layer 1 is preferably made of a soft, shock-absorbing material,such as gels, fabrics, foams, recycled material, or plastic materialscommon to comfort-based, standard orthotics. Support layer 2 providesstability for the user's foot, as well as support for the embeddeddevice. It is preferably constructed of a structural material, such ashard plastics, composites, metals, foams, recycled material or any otherstructural material suitable for the base of an insole, and provides astep-down surface to protect any mechanical or electrical systemsembedded within embedded systems cavity 5. Embedded systems cavity 5 maybe of any shape depending on the design of the particular embeddedsystem, and may include channels for antenna, wires or other parts whichare required to be positioned external to the insole (not shown). In asecond embodiment of the invention, support layer 2 may comprise atwo-part construction defining a cavity on the interior thereof suchthat the embedded system is completely encased by the rigid material ofsupport layer 2. In such cases, the two parts of support layer 2 may beattached to each other using methods similar to those used to attach thewhole support layer 2 to comfort layer 1. In other embodiments, theembedded systems may be manufactured already permanently ornon-permanently encased in support layer 2, ready to be joined withcomfort layer 1.

The length of support layer 2 will preferably not exceed the length fromthe heel to arch point 4. Comfort layer 1 may be attached to the topside of support layer 2 using grooves, pegs, friction-inducing fixtures,adhesives or other fixtures in the materials. In the embodiment shown,two pads 6 are shown to represent a hook and loop attachment method,such as Velcro®. The strips are orthogonal to the user's foot, but otherembodiments could be in any arrangement on the outward faces of supportlayer 2 and comfort layer 1.

In another embodiment, comfort layer 1 would be thicker at the heel endwith a separate pocket for support layer 2. Support layer 2 would thenfit into a fabric pocket to be fastened to comfort layer 1 (not shown).In this embodiment, the fabric pocket would replace the strips ofattachment material 6 seen in the embodiment of FIG. 1. In yet anotherembodiment, comfort layer 1 may define a cavity in the heal portionthereof into which support layer 2 may be inserted (not shown).

We claim:
 1. A segmented insole comprising: a bottom, support layer; anda top, comfort layer, said top layer defining one or more surfacesdesigned to mate with said bottom layer; wherein said bottom layer iscomposed of a semi-rigid structural material and defines a cavitytherein for holding an embedded device; and further wherein said toplayer covers said bottom layer.
 2. The segmented insole of claim 1further comprising one or more attachment points wherein said bottomlayer and said top layer are attached to each other.
 3. The segmentedinsole of claim 1 further comprising an attachment method for attachingsaid bottom layer to said top layer at said one or more attachmentpoints.
 4. The segmented insole claim 3 wherein said attachment methodcomprises an attachable and detachable material.
 5. The segmented insoleof claim 3 wherein said attachment method comprises an adhesive.
 6. Thesegmented insole of claim 3 wherein said attachment method comprisesfriction-inducing fixtures, grooves, or pegs.
 7. The segmented insole ofclaim 1 wherein said top layer has cut-to-fit sizing lines.
 8. Thesegmented insole of claim 1 wherein said bottom layer and the portion ofsaid top layer not covering said bottom layer each define a bottomsurface, said bottom surface defining treads for engaging the base of ashoe into which said insole is disposed.
 9. The segmented insole ofclaim 1 wherein said top layer is composed of a shock-absorbingmaterial.
 10. The segmented insole of claim 9 wherein said top layer iscomposed of a material which is softer than said bottom layer.
 11. Thesegmented insole of claim 9 wherein said shock-absorbing material isselected from a group consisting of gels, fabrics, foams, recycledmaterials and soft plastic materials.
 12. The segmented insole of claim1 wherein semi-rigid structural material is selected from a groupconsisting of hard plastics, composites, metals, foams and recycledmaterials.
 13. The segmented insole of claim 3 wherein said attachmentmethod consists of a cavity defined in said top layer for acceptinginsertion of said bottom layer therein.
 14. The segmented in sole ofclaim 13 wherein said cavity is composed of the same material as saidtop layer.
 15. The segmented insole of claim 13 wherein said cavity iscomposed of a fabric attached to said top layer.
 16. The segmentedinsole of claim 1 wherein said bottom layer defines one or more groovesor channels therein to allow for exposure of portions of said embeddeddevice external to said insole.
 17. The segmented insole of claim 16wherein said bottom layer comprises two parts which, when joined, encasesaid embedded system inside of said bottom layer.
 18. The segmentedinsole of claim 17 wherein said bottom layer permanently encases saidembedded system.